CAT Bucyrus VT650D XP Operation Manual BI002303 – PDF DOWNLOAD

Description

CAT Bucyrus VT650D XP Operation Manual BI002303 – PDF DOWNLOAD

FILE DETAILS:

CAT Bucyrus VT650D XP Operation Manual BI002303 – PDF DOWNLOAD

Language : English
Pages : 342
Downloadable : Yes
File Type : PDF

DESCRIPTION:

CAT Bucyrus VT650D XP Operation Manual BI002303 – PDF DOWNLOAD

About this manual:
This chapter provides important information making it easier for you to use this manual. You will
also be given information on the structure of the manual and the symbols and characters used.

• The operating manual must be accessible at all times to all persons working on or with the machine.
  It should, if possible, always be avail- able at the place of operation.
• Send for a new operation manual immediately if the present manual is no longer complete or has

  become illegible.

TABLE OF CONTENTS:

CAT Bucyrus VT650D XP Operation Manual BI002303 – PDF DOWNLOAD

1 About this manual
About this manual 1 3
Before starting to work 1 3
Who is this operating manual intended for? 1 3
What is the purpose of this operating manual? 1 4
Characters and symbols 1 5
2 Your safety
Your safety 2 3
Personnel 2 4
Operation 2 4
Installation and repair 2 4
Operating conditions 2 5
Intended use 2 5
Unauthorized use 2 5
Safety instructions 2 7
General rules: 2 7
Storage and transport 2 8
Pre-start inspection 2 8
Installation and start-up 2 9
Operation 2 9
Stopping 2 10
Maintenance and repair 2 10
Diesel emissions 2 11
Handling of hydraulic fluids 2 13
Overview of the safety instructions 2 17
Chapter 2: Safety instructions 2 17
Chapter 3: Storage and transport 2 17
Chapter 4: Installation 2 17
Chapter 5: Operation 2 18
Chapter 6: Technical data 2 27
3 Storage and transport
Storage and transport 3 3
Storage 3 3
Storage of the machine and spare parts 3 3
Transport 3 4
Before transport 3 5
4 Installation
Installation 4 3
Points to observe prior to installation 4 3
Who is allowed to carry out installation? 4 3
Which tools are required for installation? 4 3
Notes on installation 4 4
Pre-installation check list 4 5
Safety features 4 6
5 Operation
Pre-operation suggestions 5 3
Operation 5 4
How to operate the VERSATRAC® 5 4
Who is allowed to operate the VERSATRAC® 5 4
When can operation be started? 5 4
Controls and indicators 5 5
Operator’s compartment – left and center 5 5
Operator’s compartment – right 5 6
Hazard zone 5 17
Starting procedure 5 18
Shutdown procedure 5 19
Towing a disabled machine 5 20
Instructions on the maintenance 5 23
Important notes 5 23
Before maintenance 5 23
Critical torque values 5 25
Lubricants, fluids and capacities 5 25
Specific lubrication and maintenance schedule 5 26
Specific lubrication and maintenance procedure 5 30
Pre-shift 5 30
Every third shift 5 33
Weekly 5 40
First 50 hours of service 5 60
Every three months 5 61
Every 100 hours 5 66
Every 500 hours 5 68
Every six months 5 70
Every twelve months 5 72
Servicing heavy duty air filter elements 5 73
Diesel emissions maintenance 5 77
Introduction (emissions) 5 77
Diesel emissions 5 77
Diesel emissions stall test 5 79
Operational issues 5 81
Best practices 5 82
Proactive attitudes 5 85
Typical exhaust gas components 5 87
Carbon dioxide 5 87
Carbon monoxide 5 87
Oxides of nitrogen 5 87
Hydrocarbons 5 87
Particulate matter 5 88
Oxides of sulfur 5 88
Smoke 5 88
Engine systems and conditions affecting diesel emissions 5 89
Combustion chamber design 5 89
Intake manifold system 5 91
Operating conditions that affect emissions 5 92
Low turbocharger boost pressure 5 93
High exhaust backpressure 5 93
High crankcase pressure 5 95
Overview of six engine systems 5 96
Overview of engine introduction 5 96
Intake system 5 97
Dry type air cleaners 5 98
Air induction piping 5 99
Aftercoolers 5 99
Air-to-air aftercoolers 5 100
Water aftercoolers 5 100
Intake system recommendations 5 101
Servicing the intake system 5 102
Job aid checklist (Intake System) 5 103
Exhaust system 5 104
Exhaust system recommendations 5 105
Exhaust after treatment system maintenance 5 106
Job aid checklist for exhaust system 5 108
Introduction to tools used for exhaust system analysis 5 109
ECOM AC+ gas analyzer 5 109
UGAS software application 5 111
Testing protocol 5 111
Pre-test conditions 5 112
Emissions testing protocol 5 112
Basic emission equipment operation 5 113
Undiluted diesel particulate measurement 5 113
Measurement interpretation 5 115
Analysis of particulate samples 5 115
Thermal optical method 5 116
Job aid checklist for exhaust system analysis tools 5 116
ECOM AC+ gas analyzer 5 117
Particulate sampling – Gilian pump 5 117
Intake testing 5 118
Intake restrictions and exhaust backpressure 5 119
Fuel injection system 5 120
Introduction (Fuel injection system) 5 120
Injection pump or injector failure 5 121
Inadequate fuel supply 5 121
Incorrect injection pump or injector timing 5 122
Advanced timing 5 122
Retarded timing 5 122
Fuel system types 5 122
Individual unit jerk pumps 5 124
Inline pump system 5 125
Distributor pump system 5 126
Cummins PT fuel system 5 126
Unit injectors 5 127
Electronically controlled fuel injection systems 5 127
Fuel injection system recommendations 5 128
Job aid checklist for fuel systems 5 129
Cooling systems 5 130
Cooling system recommendations 5 130
Cooling system maintenance 5 131
Coolant mixture 5 131
Conditioner and inhibitors 5 131
Cleaning and flushing 5 132
Troubleshooting 5 132
Thermostats 5 132
Aeration in coolant 5 132
Radiator cap relief valve 5 133
Temperature probe 5 133
Job aid checklist for cooling system) 5 134
Diesel fuel and fuel supply systems 5 135
Introduction (Diesel fuel and fuel supply systems) 5 135
Best practice recommendations 5 135
Sulfur content 5 136
Cetane number 5 136
Viscosity 5 136
Flashpoint 5 136
Fuel quality and handling recommendations 5 137
Lubrication 5 138
Lubrication recommendations 5 138
Lubrication classification 5 139
Combined service applications 5 140
Lubrication system checks 5 140
Conclusion 5 141
Diesel emissions – job aid check list 5 142
Hydraulic system 5 143
Adjustment procedures 5 145
Pressure compensated (PC) control 5 145
Main relief valve 5 146
Steering section port relief valves 5 147
Pressure limiter 5 147
Pressure reducing valve 5 148
Bell crank bi-directional valve 5 148
Auxiliary relief valve 5 150
Dif-lok valve 5 151
Hand pump relief valve 5 152
Replacement of wear parts 5 153
Tire/wheel installation 5 153
Axle removal/installation 5 157
Drive shaft removal/installation 5 160
Accumulator operation/precharging 5 161
Ejector blade and cylinder removal/installation 5 163
Canopy/cab removal 5 165
Steering cylinder 5 166
Tilt cylinder 5 168
Lift cylinder 5 170
Brake bleeding procedure 5 172
DST Dry System™ 5 173
On-board Cleaning System™ 5 173
Background 5 173
Activating 5 173
Diagnosing high exhaust backpressure 5 175
Procedure to replace the particulate filter 5 177
Replacement exhaust particulate filters 5 178
Pre-operating inspection 5 179
MSHA requirements 5 179
System requirements 5 179
Pre-operating inspection checklist 5 180
Operating instructions 5 181
Background 5 181
Starting the engine 5 181
Starting a cold engine (after extended parking) 5 182
Automatic safety shutdown features 5 183
Manual shutdown features 5 184
Excessive idling 5 184
Operating recommendations 5 184
Stopping the engine and parking the machine 5 185
Carbon Monoxide (CO) sampling procedure 5 186
Background 5 186
Reasons for monitoring engine-out CO emissions 5 187
Reasons for monitoring treated CO emissions (opt) 5 187
Permanently installed CO sampling ports 5 188
CO sampling procedure 5 189
CO sampling instruments 5 190
Maintenance for flameproof ports 5 191
CO sampling recordkeeping (sample form) 5 192
Cooling system filling procedure 5 193
Safety shutdown system 5 194
System description (pneumatic system) 5 194
Starting the system 5 195
Manual system shutdown 5 195
Manual emergency shutdown 5 195
Automatic temperature shutdown feature 5 195
Automatic low oil pressure shutdown feature 5 196
MSHA documentation 5 197
Machine permissibility (drawing 624309) 5 197
Power package permissibility (drawing M255-001-01) 5 205
Electric package permissibility (drawing M261-008-01) 5 217
General arrangement (drawing 624312) 5 222
Electrical schematic (drawing M261-003-01) 5 224
Electrical installation (drawing M261-010-01) 5 225
Alternator installation (drawing M250-107-01) 5 226
Starting circuit – Cummins 8 3 (drawing M250-012-01) 5 227
Cooling system (drawing M250-008-01) 5 228
Water injection system, pneumatic (drawing M265-006-01) 5 229
CO monitoring ports (drawing M250-006-01) 5 230
Shutdown system (drawing M250-007-01) 5 231
Fuel system, C8 3 (drawing 624310) 5 232
Operator’s compartment (drawing 624311) 5 233
Troubleshooting procedures 5 235
Hydraulic system (general) 5 236
Brakes 5 239
Hydraulic cylinders 5 240
Hydraulic pump 5 242
Valves 5 244
Engine 5 245
Converter 5 256
Transmission 5 258
Fuel injector 5 259
Compressor 5 259
Leaking intake system 5 261
Air intake system restriction and fuel flow 5 261
Catalyst failure 5 261
Exhaust particulate filter failure 5 261
6 Technical data
Technical data 6 3
Components of the VT650D Permissible VERSATRAC® 6 3
Technical data 6 3
Tightening torques 6 4
Permissible data 6 11
Lubrication fluids and greases 6 11
7 For your information
For your information 7 3
Our service 7 3
Service address 7 3
Rebuild facility address 7 4

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PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

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